1.8 turbo cylinder head removal help

[kninio]

am taking off cylinder head of audi tt 180 i didnt remove the turbo i am taking off the cylinder head with the exhaust manifold and turbo still attached to it , but am stuck it look like its sticking some where i cant take it off the car any one have experience with it? shall i remove the turbo or how is the diy? any help will be appreciated.

[mcandmar]

I rebuilt the head on a 225bhp TT (timing belt failed) which i assume is very similar. On that car the turbo is bolted to the manifold with three bolts located on the top of the manifold, undo those and the turbo/downpipe will stay in place so you only have to remove the manifold with the head.

[kninio]

I figure out that after i tortured myself with removing the whole head with the turbo its really heavy piece of metal , and the head is not repairable , cos the rust has eating most of it.. i will post pics soon


do u have an idea if the 150 hp of the golf gti can fit the audi tt 180 hp? what is the difference between them that make additional 30 hp biger turbo and remap? or just difference camshafts too? cos am going to get it new engine and the tt one is rare and very expensive compared to the vw one

[mcandmar]

Wow fair play to you. I do not fancy having to remove a turbo from one of those cars. The timing belt and head rebuild was enough, i hope i never have to work on another 1.8t ever again, give me a 5cyl any day

Dont know about the 150bhp heads, i "think" there was a few heads for the 1.8t with different sized valves or ports. And i dont think all versions had the variable cam timing. I'm sure others will chime in with more knowledge / experience with those motors. I know JP is familiar with them, he helped me out sourcing parts to rebuild it.

Out of interest whats wrong with the head on the car, seems unusual for rust to be a problem on a car that age?

[kninio]

i cant wait to have job done for this 1.8 t too , cos its no fun at all , really small area and and everything is annoying while working on it , the coolant was very red rusty water , i think they didnt put for it g12 since years and used regular drink water which rusted the head and killed it, the engine it have is ATC which doesnt have variable cam shafts the car is year 2000 , maybe 2001+ had the variable chain tensioner for the cams.

[kninio]

pictures of rusts

[speeding-g60]

i would send that head thru the cleaners.... aluminum doesnt rust.

that said. the differences of the 180hp motor... and the 150 hp.

does the 150 hp have SAI? or is it an AEB code head? also, the VVT cam chain tensioner. it has an electrical solenoid on it whereas the aEB does not.

if the new (150 hp) head still has the SAI (smog pump) it will have the VVT, and there will be no difference in your application. the difference was compression and turbo mostly.

the AEB head came on longitudinal cars, the B5 A4 1.8T and the B5 Passat 1.8T.... i dunno about over there but it NEVER CAME transverse in USA.

there is no difference in cams until you start talking about the N/A 1.8 20v, which does have different cams (so i read, we didnt get that one here either.)

LMK if you have anymore 1.8T 20v ?'s, i happen to know just a little bit.....

[mac2226]

1.8t

Hi the 150bhp engines have bigger intake ports and manifold witch is good if going hi side of 350+ but slower spool up, where as the small port have faster spool up.The difference in 150/180 is 70bhp when custom mapped with all usual add ons ic tip em dc 4bar fpr turbo back exaust been down this route and forget how nice it was to drive with this setup.

[kninio]

i would send that head thru the cleaners.... aluminum doesnt rust.

that said. the differences of the 180hp motor... and the 150 hp.

does the 150 hp have SAI? or is it an AEB code head? also, the VVT cam chain tensioner. it has an electrical solenoid on it whereas the aEB does not.

if the new (150 hp) head still has the SAI (smog pump) it will have the VVT, and there will be no difference in your application. the difference was compression and turbo mostly.

the AEB head came on longitudinal cars, the B5 A4 1.8T and the B5 Passat 1.8T.... i dunno about over there but it NEVER CAME transverse in USA.

there is no difference in cams until you start talking about the N/A 1.8 20v, which does have different cams (so i read, we didnt get that one here either.)

LMK if you have anymore 1.8T 20v ?'s, i happen to know just a little bit.....

this head of 180HP , engine code is ATC and yes it have smog pump but it doesnt have vvt this is american engine for US market only it doesnt exist in europe , so i can understand from u i can use engine from golf 4 gti? if it have same cylinder head with out vvt ? the aluminiun didnt rust but something has eating it look at the picture below and u will see how it become..

[speeding-g60]

the early small port motors in the US were still 150 hp.

ALL smog pump motors are small port (in USA). the early ones (engine code ATW) were 150 hp with small port, SAI, and NO VVT.

the AEB was the only large port, had NO SAI, and NO VVT.

i have personally run any head/block combo you can have. internal water pump (06A family) with large or small port. and AEB/external water pump (058 family) with small port and large port. and i have also used both style cam chain tensioners in both style heads as well.

if the head has SAI, it will be a bolt on affair, just swap the cam chain tensioner. also, the cam gear must match the block originally used, as the internal and external blocks had a different offset. and lastly, the cam trigger has a different sensor (1 window for early AEB style, 4 window for later small port style).

not all 150 hp motors are large ports.

and from PERSONAL EXPERIENCE, and i have a fair bit of it, i notice more AWHP and less torque running a ported small port head while at the same time i notice more torque and less AWHP with a non ported large port head. and the ported small port even had bigger displacement (83mm bore > 82mm bore) which would make a person think otherwise....

my setup is the only 4cyl Audi to run a 9 sec 1/4 mile in North America, and one of only two in the world. its been tuned (lightly) at 648 AWHP/480 wtq with only 32-33 psi....

[kninio]

yes the engine i have is small ports , and it have smog pump and egr valve, i make a tour in the city today and i found two engines one is AYP from seat ibiza cupra and another one from audi a3 , the a3 one is in better conditions but it have broken bolt mount in the cylinder block and it have turbo KO3 , which is identical for the one on the early tt , is that mean the difference between the 150 hp and 180 hp just remap ?? since the share the same turbo? the seat one have oposide side for the throtle body but it look like a bit dirty... any sugestion how to inspect turbo engine virtualy if its off the car?